Method and composition for waterproofing

ABSTRACT

A method and composition for waterproofing a substrate herein is described which includes applying a coating composition to a surface of the structural unit. The coating composition includes a) an organic solvent, b) a hydrocarbon resin and c) a styrene polymer, having a styrene content of about 60 wt % or greater, selected from the group consisting of a copolymer having styrene and diene monomer units, a copolymer having styrene and olefin monomer units, a polymer having styrene monomer units and mixtures thereof.

RELATED APPLICATIONS

[0001] This is a continuation of U.S. Ser. No. 09/628,709, filed Oct. 3,2001, which is a divisional of U.S. Ser. No. 09/304,354, filed May 4,1999, which applications are expressly incorporated herein.

FIELD OF THE INVENTION

[0002] The present invention relates to a method and a polymericcomposition for waterproofing. More particularly, the present inventionrelates to a method and composition using an organic solvent, ahydrocarbon resin and a polymer having at least one styrene-containingpolymer to form a waterproof film.

BACKGROUND OF THE INVENTION

[0003] Structures used in construction, such as foundations and walls,include materials, such as masonry, cement, wood, plaster, stone, clayor brick that may be porous. Such porous materials are susceptible tocracking and can be degraded by water and/or loss of water from theporous materials. Below grade structures are often subjected tohydrostatic pressure from ground water. Above grade structures aresubject to precipitation and water from other sources. A variety ofmethods and products for waterproofing and/or sealing these structuresagainst outside water have been developed.

[0004] One type of waterproofing and/or sealing system includespolyvinyl or polyethylene sheeting adhered or fastened to the surface ofthe structure. If an adhesive is used to adhere the sheeting to thestructure, the adhesive may not stick well due to dust (e.g., cement orstone dust) produced during construction and other activities and loseits adhesion over time. On the other hand, if fasteners, such as nailsor staples, are used to attach the sheeting to the structure, thefasteners typically puncture the sheeting and the structure beneath,providing a channel through which water can flow. Moreover, there areseams between the sheets that require the use of a fastener or adhesiveto close. The adhesive may be attacked by microorganisms and/oroxidation and degraded or may dissolve in water over time, allowingwater to flow through the seam. Fasteners puncture the sheeting andallow water through the resulting holes. In addition, the waterproofingsheets are often difficult to form around non-uniform structures andadverse weather conditions may hinder the placement of the sheets on thestructure. For example, wind may cause wrinkles in the sheet as it ispositioned on the structure and, on very cold days, the sheets may tearor even shatter during installation.

[0005] Another type of waterproofing and/or sealing system includes theapplication of a coating composition on the structure. One common typeof coating composition for waterproofing and sealing is tar- orasphalt-based. Although these compositions are relatively inexpensiveand can be applied year-round, the materials in the composition oftenleach away from the wall. This often contaminates the soil and reducesthe amount of protection afforded by the coating. Moreover, thesecompositions typically contain a large amount of organic material whichmay be attacked by soil- or water-borne microorganisms, thereby reducingthe effectiveness of the coating.

[0006] Other types of coating compositions have been developed. Many ofthese coating compositions, however, do not produce a durable film overporous substrates (e.g., cement, masonry blocks, wood, etc.). Often, thefilm that is formed using these coating compositions is easily puncturedand/or includes components that are degradable or leach away from thefilm thus losing its adhesion to substrates. These coating compositionsneed to be applied with a significant amount of volatile organiccompounds as solvents. These emitted volatile organic compounds (VOCs)are limited by current environmental regulations. Moreover, a number ofthe coating compositions are difficult to apply and/or relativelyexpensive.

[0007] There is a need for alternative waterproofing and/or sealingcompositions which emit less volatile organic compounds uponapplication, are durable, possess a long life span, and stable in belowgrade and above grade applications. In addition, new compositions andsealing structures are needed which are useful year round, even innorthern latitudes. Such compositions may also be useful for coatingother substrates, as well.

SUMMARY OF THE INVENTION

[0008] The present invention relates to methods and compositions forwaterproofing and sealing a surface of a substrate. One embodiment is amethod of waterproofing a surface of a substrate. The method includesapplying a coating composition to the surface of the substrate. Thecoating composition includes a) an organic solvent, b) a hydrocarbonresin and c) a styrene polymer, having a styrene content of about 60 wt% or greater, selected from the group consisting of a copolymer havingstyrene and diene monomer units, a copolymer having styrene and olefinmonomer units, a polymer having styrene monomer units and mixturesthereof.

[0009] A further embodiment is a method of waterproofing a surface of asubstrate. This method includes applying a coating composition to thesurface of the substrate. The coating composition includes: a) anorganic solvent, b) about 1 to about 85 phr of a coumarone-indenepolymer; and c) about 15 to about 99 phr of a styrene polymer, having astyrene content of about 60 wt % or greater, selected from the groupconsisting of a copolymer having styrene and diene monomer units, astyrene homopolymer and mixtures thereof.

[0010] Another embodiment is a method of applying a waterproofingcoating to a structural unit. A coating composition is applied to asurface of the structural unit. The coating composition includes; a)about 20 to 400 phr of an organic solvent, b) about 1 to 65 phr of acoumarone-indene polymer, c) about 35 to 99 phr of a styrene polymer,having a styrene content of about 60 wt % or greater, selected from thegroup consisting of a copolymer having styrene and diene monomer units,a styrene homopolymer and mixtures thereof, and d) about 20 to 600 phrof a filler. The coating composition is then dried to form a film.

[0011] A further embodiment of the invention is a waterproofingcomposition. The waterproofing composition includes; a) about 33 phr toabout 250 phr of an organic solvent, b) about 10 to 50 phr of acoumarone-indene polymer; c) about 50 to 90 phr of a styrene polymer,having a styrene content of about 60 wt % or greater, selected from thegroup consisting of a copolymer having styrene and diene monomer units,a styrene homopolymer and mixtures thereof.

[0012] Yet another embodiment of the invention is a waterproofingcomposition. The waterproofing composition includes; a) about 50 toabout 150 phr of an organic solvent, b) about 30 to 50 phr of acoumarone-indene polymer, c) about 50 to 70 phr of a styrene polymer,having a styrene content of about 60 wt % or greater, selected from thegroup consisting of a copolymer having styrene and diene monomer units,a styrene homopolymer and mixtures thereof.

[0013] The above summary of the present invention is not intended todescribe each disclosed embodiment or every implementation of thepresent invention. The detailed description which follows moreparticularly exemplify these embodiments, but do not limit the scope ofthe invention, as defined by the claims.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0014] The present invention is believed to be applicable to methods andcoating compositions for waterproofing and/or sealing a surface of asubstrate. In particular, the present invention is directed to methodsand coating compositions using a combination of a) a hydrocarbon resinand b) one or more styrene polymers, having a styrene content of about60 wt % or greater, and having styrene monomer units and usually, butnot necessarily, diene monomer units or olefin monomer units or mixturesof these polymers. While the present invention may not be so limited, anappreciation of various aspects of the invention will be gained througha discussion of the examples provided below.

[0015] The term “polymer” includes homopolymers and copolymers, unlessotherwise indicated.

[0016] The term “hydrocarbon resin” is a term that is used to describe alow molecular weight thermoplastic polymer synthesized via the thermalor catalytic polymerization of coal-tar fractions, cracked petroleumdistillates, terpenes, or pure olefinic monomers.

[0017] The term “monomer unit” indicates a unit of a polymer which isderived from or has the same chemical structure as a unit derived from aparticular monomer.

[0018] The term “phr”, as used herein, is a unit of measurement whichindicates the number of parts by weight of a particular component in acoating composition having 100 parts by weight of a polymeric binderresin.

[0019] The term “substrate” includes any surface that is capable ofbeing coated with the composition of the invention.

[0020] A preferred substrate is a “structural unit.” The term“structural units” includes, by way of example, foundations, basementwalls, retaining walls, cement posts, other building walls, dry wall,pool enclosures, tub and shower enclosures, highway structures (e.g.,posts and walls), wooden or metal fence posts, sheet rock, plywood,wafer board, wall sheeting, pressed board, containment basins and walls,fabricated walls, floor panels, roofs, plaza decks, decks, floors,concrete, pre-stressed concrete other substrates that are buried or areexposed to water or weathering conditions, and the like. Thesestructural units are typically made from masonry, cement, wood, plaster,stone, gypsum, clay, brick, tile, terra cotta, cardboard, paper, and thelike.

[0021] A coating composition for waterproofing or sealing a structuralunit or any other substrate has a polymeric binder resin in an organicsolvent. In addition, the coating composition may optionally have afiller, a pigment or dye, and/or a plasticizer. Other optionalcomponents of the coating composition include, for example, anantioxidant, a UV (ultraviolet) absorber or blocker, an ozone blocker, afoaming agent, a tackifier, a perfume, and/or a deodorizer. Typically,the coating composition includes 100 parts by weight of a polymericbinder resin, about 20 to 400 phr of an organic solvent, 0 to about 600phr of a filler, 0 to about 10 phr of a pigment or dye, and 0 to about50 phr of a plasticizer. Other optional components of the coatingcomposition are typically available in amounts ranging from 0 to about10 phr.

[0022] The polymeric binder resin is a combination of (a) a hydrocarbonresin and (b) one or more styrene polymers, having a styrene content ofabout 60 wt % or greater, and having styrene monomer units and usually,but not necessarily, diene monomer units or olefin monomer units ormixtures of these polymers. The components of the binder resin arechosen based on the desired properties of the composition and resultingfilm.

[0023] The use of a hydrocarbon resin component in the polymeric binderresin is cost efficient by reducing the required amount of more costlypolymeric components in the polymeric binder composition. The use of thehydrocarbon resin also reduces the amount of volatile organic components(VOCs) needed in the composition. This reduction of solvent directlylowers VOC emissions during all stages of the production, storage andapplication process of the coating composition. The hydrocarbon resinfurther improves the processability of the polymeric binder resin bylowering the overall molecular weight and viscosity of the resin. Thelower viscosity aids in the application of the resin to the substrate.The use of a hydrocarbon resin also improves the flexoral modulus, andgives lower gas and vapor permeation rates to the resulting film. Thehydrocarbon resin enhances the adhesive and elongation properties of thecomposition and resulting film. The resulting film is a non-tacky,flexible, and tough coating. The hydrocarbon resin also promotescompatibility of the components in the composition. Any amount ofhydrocarbon resin in the polymeric binder resin provides the abovementioned advantages.

[0024] The styrene component of the polymeric binder resin provideshardness and durability to a film formed from the coating composition.The diene component increases the flexibility and the impact resistanceof the resulting film. The olefin component gives the film increasedelasticity and resistance to oxidation and degradation due to, forexample, ultraviolet light, ozone, and other chemical agents in theatmosphere or soil.

[0025] Hydrocarbon Resin

[0026] Hydrocarbon resins used in accordance with the invention are lowmolecular weight polymers (oligomers) produced from by-producthydrocarbon, petroleum or coal tar streams. Polymerization is carriedout using any one of a number of acid catalysts or as a free radicalreaction using heat and pressure. The hydrocarbon resins include bothnatural and synthetic types; aliphatic and aromatic. Preferredhydrocarbon resins include coumarone-indene resins. Molecular weights ofthe hydrocarbon resins range from about 200 up to about 2000, andpreferably range from about 350 to about 1000.

[0027] Coumarone-indene resins (polymers) suitable for use in the blendsof this invention generally can include those resins obtained throughcatalytic polymerization of coal-tar naphthas. Although named after twoparticular components of these resins, coumarone (I) and indene (II),these resins are actually produced by the cationic polymerization ofpredominantly aromatic feedstocks. These feedstocks, such as, coal-tarnaphthas contain resin-forming materials, for example, styrene,coumarone, indene, methyl coumarones, methyl indenes,dimethylcoumarones, dicyclopentadiene, methyl cyclopentadienes,cyclohexadienes, naphthalene, and anthracene derivatives.

[0028] Polymerization of these resin-forming materials is effected bythe catalytic action of a Bronsted acid, such as sulfuric acid or aderivative thereof, or of a Lewis acid, such as stannic chloride,antimony pentachloride, aluminum chloride, titanium tetrachloride, orboron trifluoride, on the coal tar naphthas. The polymers, generally,are not homopolymers, but are derived from mixtures of severalresin-forming materials. The polymers may also be condensed with phenoland derivatives thereof, or with lower aliphatic aldehydes such asformaldehyde, or may be hydrogenated to remove residual unsaturation.Such hydrocarbon resins are commercially available and include, forexample, polyindenes, polycoumarones, coumarone-indene polymers,phenol-modified coumarone-indene polymers, coumarone-indene-styrenepolymers, styrene-cyclopentadiene polymers, styrene-indene polymers,dicyclopentadiene resins, terpene resins, naphthalenic resins,anthracenic resins, lignin and the like.

[0029] Any amount of hydrocarbon resin added to the polymeric binderresin improves the polymeric binder resin properties as stated above.Typically the hydrocarbon resin may be present in the polymeric binderresin in an amount up to about 85 phr and preferably up to about 65 phr.Further useful ranges of hydrocarbon resin present in the polymericbinder resin include about 10 to 50 phr and more preferably 30 to 50phr.

[0030] The most preferred hydrocarbon resins are commercially availablemodified coumarone-indene polymers including, for example, Nevex® 100and Cumar® from Neville Chemical Company. Vantack® 85, 95 and 105 seriesresins from Vanderbilt Chemical Co., may also be used.

[0031] Polymers

[0032] The polymer typically includes a combination of up to three typesof polymers. These three types include a) styrene-diene copolymershaving a styrene content of 60 wt. % or greater and typically from about85 to 99 wt. % and, preferably, from about 90 to 99 wt. %, b) acopolymer having styrene and olefin monomer units with a styrene contentof 60 wt. % or greater, and c) polymers having styrene monomer unitswith a styrene content of 60 wt. % or greater and typically from about85 to 99 wt. % and preferably, from about 90 to 99 wt. %. Thecombination of polymers are typically chosen to produce a durable filmwith elastomeric properties.

[0033] The amounts of each type of polymer in the polymeric binder resinmay be representative of a single polymer or copolymer or a combinationof polymers and/or copolymers. The polymers used in the polymeric binderresin may be virgin polymers, reground polymers, recycled polymers, ormixtures thereof.

[0034] Typical diene monomer units include butadiene and isoprene.Butadiene is the preferred diene monomer unit. Typical olefin monomerunits include ethylene, propylene, butylene (i.e., 1-butene andisomers), and isobutylene (i.e., isobutene). Preferred olefin monomerunits include ethylene, butylene, and isobutylene.

[0035] The polymeric binder resin includes a polymer having a relativelyhigh styrene-content (styrene content greater than 60 wt. %.) Thehigh-styrene content polymer may increase the hardness and durability ofa film formed from the coating composition. This high styrene-contentpolymer may be a styrene homopolymer or a copolymer of styrene with, forexample, one or more diene, olefin, acrylonitrile, and/or acrylatemonomer units. Suitable high styrene-content polymers include, forexample, polystyrene homopolymer, high impact polystyrene (HIPS), andmedium impact polystyrene (MIPS). Both HIPS and MIPS are oftencopolymers of styrene and a diene, such as butadiene. HIPS and MIPStypically have a styrene content that ranges from 60 wt. % to 99 wt. %.Typically HIPS has a styrene content of least about 85 wt. % andpreferably at least about 90 wt. %. Typically MIPS has a styrene contentof least about 85 wt. % and preferably at least about 95 wt. %.

[0036] The impact resistance of films formed using coating compositionshaving high styrene-content polymers typically increases as the overalldiene content increases. The diene content of the coating compositionmay be modified, for example, by using a polymer with higherdiene-content or decreasing the amount of the high styrene-contentpolymer in the polymeric binder resin. The impact resistance of the filmmay also be modified by the addition of a plasticizer. On the otherhand, the hardness of films formed using these polymers typicallydecreases as the diene content increases. Thus, the desired propertiesof the film may be tailored by varying the polymeric binder resincomposition.

[0037] Polymers with styrene a content of less than 60 wt % may beoptionally added to the polymeric binder resin. These polymers includestyrene-diene copolymers and styrene-olefin copolymers. One example of asuitable styrene-diene copolymer is a styrene-diene-styrene triblockcopolymer which has two endblocks of polymerized styrene monomer unitsseparated by a central block of polymerized diene monomer units.Suitable triblock polymers include, for example,styrene-butadiene-styrene (S-B-S) polymers and styrene-isoprene-styrene(S-I-S) polymers. Commercial S-B-S and S-I-S polymers include, forexample, many of the Kraton® D 1100 Series polymers from Shell ChemicalCompany (Houston, Tex.) and Stereon® Block Copolymers from FirestoneSynthetic Rubber & Latex Co. (Akron, Ohio). For example, Kraton® D 1101and D 1102 are S-B-S polymers and Kraton® D 1107 is an S-I-S polymer.These copolymers typically have a styrene-content of about 5 to 60 wt %and usually about 10 to 35 wt %.

[0038] Another example of a suitable styrene-diene copolymer is astyrene-diene diblock polymer, such as a styrene-butadiene (S-B)copolymer or a styrene-isoprene (S-I) copolymer. Commercially availabletriblock polymers often include at least some diblock polymer.

[0039] The styrene-diene copolymer portion of the polymeric binder resinmay include at least one block copolymer. Random copolymers may also beused, particularly in combination with a block copolymer or copolymers.

[0040] The polymeric binder resin may include at least onestyrene-olefin copolymer with a typical styrene-content less than 60 wt.% and preferably ranging from about 10 to 60 wt. %, and more preferably,about 20 to 50 wt. %. Such copolymers combine the hardness of thestyrene monomer units with the elastomeric properties of the olefinmonomer units. The styrene-olefin copolymer portion of the polymericbinder resin typically includes at least one block copolymer, however,random copolymers may also be used, particularly in combination withblock copolymers. Examples of styrene-olefin copolymers includestyrene-ethylene-butylene-styrene (S-EB-S) block copolymers,styrene-ethylene-propylene-styrene (S-EP-S) block copolymers,styrene-ethylene-butylene (S-EB) block copolymers, andstyrene-ethylene-propylene (S-EP) block copolymers. Examples of thesecopolymers include Kraton® G 1600 and 1700 series polymers and Kraton®FG 1900 series polymers. A preferred polymer of this type is thestyrene-ethylene-butylene-styrene polymer, such as, for example, many ofthe Kraton® G 1600 Series polymers, including Kraton® G 1650 and 1652polymers.

[0041] The polymeric binder resin may additionally include at least onepolyolefin. Suitable examples of polyolefins include polyethylene,polypropylene, and polybutene. Preferred polyolefin includepolyethylene, polybutene, polyisobutylene, and polymers having acombination of butylene and isobutylene monomer units (e.g., a polymerhaving about 25 to 30 wt. % isobutylene monomer units and about 70 to 75wt. % butylene monomer units) . Polyolefins may be obtained from avariety of manufacturers and distributors.

[0042] In one embodiment of the invention, the polymeric binder resinincludes: a) about 1 to 85 phr hydrocarbon resin: b) about 15 to 99 phrof a styrene polymer, having a styrene content of about 60 wt % orgreater, selected from the group consisting of a copolymer havingstyrene and diene monomer units, a styrene homopolymer and mixturesthereof.

[0043] In another embodiment of the invention, the polymeric binderresin includes: a) about 1 to 65 phr, preferably about 10 to 50 phrcoumarone-indene polymer; b) about 35 to 99 phr, preferably about 50 to90 phr of a styrene polymer, having a styrene content of about 60 wt %or greater, selected from the group consisting of a copolymer havingstyrene and diene monomer units, a styrene homopolymer and mixturesthereof.

[0044] In another embodiment of the invention, the polymeric binderresin includes: a) about 30 to 50 phr coumarone-indene polymer; b) about50 to 70 phr of a styrene polymer, having a styrene content of about 60wt % or greater, selected from the group consisting of a copolymerhaving styrene and diene monomer units, a styrene homopolymer andmixtures thereof.

[0045] Solvent

[0046] The polymers and hydrocarbon resins that form the polymericbinder resin are dissolved and/or dispersed in an organic solvent toform a coating composition. The amount of solvent used determines thedrying time, and appropriate method of application for the coatingcomposition. A variety of solvents may be used. Suitable solvents whichare commonly used include, for example, aromatic hydrocarbons,cycloaliphatic hydrocarbons, terpenes, unsaturated hydrocarbons, organiccarbonates, and halogenated aliphatic and aromatic hydrocarbons.Suitable solvents include toluene, xylene, benzene, halogenated benzenederivatives, ethyl benzene, mineral spirits, naphtha, cyclohexane,methylene chloride, ethylene chloride, trichlorethane, chlorobenzene,propylene, ethylene carbonate, nitropropane, acetone, ethyl acetate,propyl acetate, butyl acetate, and isobutyl isobutyrate. Preferredsolvents are aromatic hydrocarbons, such as toluene, xylene, benzene,and halogenated benzene derivatives, as well as mineral spirits.

[0047] For environmental reasons, it is desirable to use as littlesolvent as possible in the coating composition. The lower limit on theamount of solvent may be determined by the amount of solvent needed tosolvate and/or disperse the components of the coating composition. Iftoo little solvent is used, then the coating composition may be tooviscous for the particular application. On the other hand, if too muchsolvent is used, the coating composition may not have the necessaryviscosity to ensure that a proper coating is deposited on the structuralunit and an excessive amount of VOCs are emitted into the environment.This can result in a film that may be thin, easily punctured, and/orhave an unacceptable amount of pinholing. In addition to the use of asolvent, the viscosity of a coating composition may often be reduced bywarming the coating composition. Surprisingly, the addition ofhydrocarbon resins to the composition reduces the amount of solventneeded to solvate and/or disperse the components of the coatingcomposition.

[0048] The use of the hydrocarbon resin reduces the amount of solvent orvolatile organic components (VOCs) needed in the composition for aspecified final film thickness. Coating a set area with a specified filmthickness emits less VOCs with the hydrocarbon resin included in thecoating composition than without the hydrocarbon resin in the coatingcomposition. This reduction of solvent directly lowers VOC emissionsduring application of the coating composition to a substrate. Lowersolvent emissions during application of the coating composition is asurprising benefit gained by using a hydrocarbon resin in the coatingcomposition.

[0049] The desired viscosity of the coating composition often depends onthe method of application of the coating composition. Coatingcompositions that are formulated for application using a brush or rollercan often be more viscous than those formulated for spraying. Thedesired viscosity may also depend on whether the surface to be coated isa vertical surface, where a less viscous coating composition may run, ora horizontal surface.

[0050] The amount of solvent in the coating composition typically rangesfrom about 20 to 400 phr, preferably from about 33 to 250 phr, and morepreferably from about 50 to 150 phr, based on 100 part by weight of thepolymeric binder resin. However, larger or smaller amounts of solventmay be used depending on the desired composition and viscosity of thecoating composition.

[0051] Optional Components

[0052] The coating composition typically includes a filler. The fillermay increase the strength of the coating composition and/or replacecostly materials of the polymeric binder resin. The filler may alsomodify the physical properties of the coating composition and filmsformed using the coating composition, including, for example, the color,opacity, affinity for other coatings, density, rheology, stiffness, andmodulus of the coating composition and/or film. Any particular fillermay have one or more of these, or other, functions in the coatingcomposition.

[0053] In addition, a coating composition with a filler may more easilyand reliably cover holes, depressions, recesses, cracks, and crevices ina substrate, for example, in masonry blocks, concrete, wood, and otherporous or rough substrates. The presence of a filler may reduce the sizeand number of pinholes in a film formed from the coating composition.These pinholes arise, at least in some cases, because of gravity and/orcapillary action that draws the coating composition into the hole,depression, recess, crack, or crevice in the substrate, creating a breakor pinhole in the resulting film. The filler often includes particlesthat, because of their larger size, provide structural support that, incombination with the polymeric binder resin, forms a film across thehole, depression, recess, crack, or crevice. This reduces the tendencyto form pinholes.

[0054] Surprisingly, the use of a hydrocarbon resin also increases theamount of filler that can be added to the coating composition.

[0055] Suitable fillers include, for example, carbonates, clays, talcs,silicas including fumed silica and amorphous silica, silico-aluminates,aluminum hydrate, metal oxides (e.g., oxides of aluminum, iron, zinc,magnesium, and titanium), silicates (e.g., mica), sand, Portland cement,carbon filaments, glass, fiberglass, cellulose, graphite, mortar powder,calcium carbonate, sulfates (such as magnesium or calcium sulfates), andthe like. Additional suitable fillers include, for example, polymericmaterials such as vinyl and other rubbers, nylon, rayon, polyesters, andthe like, as well as combinations thereof, particularly combinations ofrubber and the other components. These polymeric materials may bevirgin, reground or recycled and may include pellets, milled or cutfibers, and other forms of the polymers. These polymeric materials donot participate in the polymeric binder resin. Preferred fillers includetitanium dioxide, oxides, clay, mica, talc, vinyl rubber, nylon, rayon,polyesters, graphite, and mixtures thereof.

[0056] The amount of filler in the coating composition typically dependson the desired properties of the composition. These properties mayinclude the strength, flexibility, ultraviolet radiation resistance,chemical resistance, permeability, and cost of the coating composition.Often more than one type of filler is used. A combination of fillers mayprovide desired advantages for the coating composition and/or overcomedisadvantages arising from other components in the film. Typically, theamount of filler ranges from 0 to about 600 phr, preferably about 10 to150 phr, more preferably, about 20 to 100 phr, and most preferably about25 to 80 phr, based on 100 parts by weight of the polymeric binderresin. Larger amounts of filler may also be used. However, if the amountof filler is too large then the polymeric binder resin may not besufficient to hold together the film formed from the coatingcomposition.

[0057] In some embodiments, the coating composition contains about 5 to60 phr, and preferably about 20 to 50 phr, of a polymeric fillermaterial, such as vinyl rubber, nylon, polyester, rayon, or combinationsthereof. These polymeric filler materials often enhance the sprayabilityand wearability of the resulting coating compositions and films.

[0058] In some embodiments, the coating composition contains about 0.1to 20 phr, and preferably about 5 to 15 phr, of a metallic oxide. Thepreferred metallic oxide is titanium dioxide.

[0059] In addition, some embodiments contain about 1 to 35 phr, andpreferably about 5 to 25 phr, of a silicate, such as mica. Mica has beenfound to be particularly useful in reducing the size and number ofpinholes.

[0060] The coating composition may optionally include a pigment or dye.The pigment or dye may impart a desired color to the coating compositionand may be added for aesthetic purposes. The pigment or dye may also beincluded in the coating composition to, for example, aid the user indetermining which portion of a surface has been covered by the coatingcomposition. The pigment or dye may also absorb light which can harm thefilm. For example, the pigment or dye may absorb one or more wavelengthsof ultraviolet (UV) light.

[0061] Pigments and dyes may be powders, lakes, metal flakes, organic ororganometallic molecules, and the like. Examples of suitable pigmentsand dyes include iron lakes, iron oxide, such a red, yellow, and blackiron oxides, other metal oxides, and carbon black. Typically, 0 to about10 phr, and preferably about 0.1 to 3 phr, of pigment or dye is used.However, larger amounts may be used. In addition to compounds usedprimarily as pigments or dyes, the coating composition may also includeother components, such as the filler material, that also act as apigment or dye. For example, titanium dioxide which may also be afiller, is a pigment. In such cases, the amount of the filler/pigment(e.g., titanium dioxide) in the coating composition may berepresentative of that described above for the filler material.

[0062] Another optional additive is an antioxidant. Polymers withstyrene and diene monomer units are unsaturated and are susceptible toattack by oxygen. An antioxidant may be added to the coating compositionto prevent the oxidation of the polymers in the polymeric binder resin.In some commercial polymers, an antioxidant is already provided with thepolymer and additional antioxidant may not be needed. For example,commercial styrene-containing and diene-containing polymers, includingthe Kraton® Series D 1100 and G 1600 polymers, already have an amount ofantioxidant added to the polymer to facilitate manufacturing, shipping,and storage. However, additional antioxidant may be added as desired orneeded.

[0063] A variety of antioxidants are known and may be included in thecoating composition. One suitable type of antioxidant includes asubstituted phenolic compound. Commercial antioxidants of this typeinclude Irganox® 1010 and 565 (Ciba-Geigy Co., Ardsley, N.Y.), Ethanox®330 (Ethyl Corp., Baton Rouge, La.), and BHT (butylated hydroxytoluene,available from a variety of sources). Other types of antioxidants mayalso be used.

[0064] The amount of antioxidant in the coating composition ranges from0 to about 10 phr. If an antioxidant is used in the coating composition,the amount of antioxidant preferably range from about 0.01 to 5 phr, andmore preferably from about 0.05 to 2 phr.

[0065] The coating composition may also include an ultraviolet (UV)absorber or blocker. This may be particularly useful in coatingcompositions that are exposed to sunlight or other sources ofultraviolet light. Examples of suitable UV absorbers or blockers includesubstituted benzotriazoles, hindered amines, benzophenones, andmonobenzoates. Commercial UV absorbers or blockers include Tinuvin®P/300 Series and Tinuvin® 770 from Ciba-Geigy Co. (Ardsley, N.Y.),Cyasorb® UV 531 from American Cyanamid (Wayne, N.J.), and Eastman® RMBfrom Eastman Chemical Co. (Kingsport, Tenn.). Other types of UVabsorbers or blockers may also be used.

[0066] The amount of UV absorber or blocker in the coating compositionranges from 0 to about 10 phr. If an UV absorber or blocker is used inthe coating composition, the amount of UV absorber or blocker preferablyrange from about 0.01 to 5 phr, and more preferably from about 0.05 to 2phr.

[0067] Ozone blockers may also be used, particularly for coatingsubstrates that will be exposed to air or to ozone-forming devices.Examples of ozone blockers include dibutyl thiourea, nickeldibutyl-dithiocarbomate (DuPont, Wilmington, Del.), Ozone Protector 80(Reichhold Chemicals, Durham, N.C.) and the like. The amount of ozoneblocker in the coating composition ranges from 0 to about 10 phr. If anozone blocker is used in the coating composition, the amount of ozoneblocker preferably range from about 0.01 to 5 phr, and more preferablyfrom about 0.05 to 2 phr.

[0068] The coating composition may also include a plasticizer. Theplasticizer may increase the toughness and flexibility of the filmresulting from the coating composition. In many cases, a plasticizer isnot needed as the combination of the polymers in the polymeric binderresin plasticize each other. However, when desired or needed anadditional plasticizer may be added. Examples of useful plasticizersinclude butyl stearate, dibutyl maleate, dibutyl phthalate, dibutylsebecate, diethyl malonate, dimethyl phthalate, dioctyl adipate, dioctylphthalate, butyl benzyl phthalate, benzyl phthalate, octyl benzylphthalate, ethyl cinnamate, methyl oleate, tricresyl phosphate,trimethyl phosphate, tributyl phosphate, trioctyl adipate phthalateesters and the like. Other plasticizers are known.

[0069] Typically, the coating composition includes 0 to about 50 phr ofplasticizer. For those embodiments that use a plasticizer, the preferredamount ranges from about 5 to 40 phr, more preferred from about 7 to 30phr, and most preferred from about 10 to 20 phr. The amount ofplasticizer used in the coating composition depends, at least in part,on the desired properties and the composition of the polymeric binderresin. Typically, the more plasticizer, the more elastic the film,however, if the amount of plasticizer is too great than the cohesivenessof the film resulting from the coating composition may decrease. Aplasticizer may be particularly useful in combination with highstyrene-content polymers.

[0070] Other components may be used in the coating composition. Forexample, it has been found that the addition of a small amount (lessthan 0.1 phr) of colloidal silica (e.g., Cab-O-Sil® M-5 or TS-610, CabotCorp., Tuscola, Ill.), particularly in combination with about 1 to 10phr of mineral spirits, causes the volume of the coating composition andthe resulting film to increase. Examples of other optional components ofthe coating composition includes for example, perfumes, deodorants,foaming agents and tackifiers (e.g., Wingtack® series tackifiers fromGoodyear Tire & Rubber Co., Akron, Ohio).

[0071] Preparation Methods

[0072] The coating composition is prepared by combining the organicsolvent with the other components, including the polymers, thehydrocarbon resin, and the optional filler, pigment, antioxidant,plasticizer, and any of the other optional components. This combinationis then mixed to dissolve and/or disperse the components within thesolvent and form the coating composition. The mixing continues for about30 minutes to 2 hours or until the coating composition appears creamyand the particles in the coating composition appear uniform as viewedthrough a falling film of the coating composition.

[0073] Various modifications can be made to this procedure. In someembodiments, the polyolefin polymer is not added until after the mixingof the solvent and the other components begins, particularly if thepolyolefin polymer is a polybutene polymer (e.g., polybutylene orpolyisobutylene). Polyolefin polymers, particularly polybutylene andpolyisobutylene, often do not disperse well in the solvent unless thepolyolefin polymer has been previously liquefied by dissolving ordispersing in a solvent, such as mineral spirits, and/or by heating. Thepolyolefin polymer may be added into the solvent mixture over a periodof time, for example, over a period of 10 minutes or less. Preferably,the polyolefin polymer is heated to a temperature ranging from about 90to 125° C. and mixed with mineral spirits prior to being poured into thesolvent mixture, as this typically enhances dispersion of the polyolefinin the solvent.

[0074] Furthermore, for those embodiments which have vinyl rubber as afiller component, it may be desirable to allow the vinyl rubber to sitin a portion of the organic solvent for fifteen minutes to 12 hoursuntil the vinyl rubber and the organic solvent form a paste. This pasteis typically added to the mixture with the rest of the components beforeor shortly after adding the solvent. The formation of a pastefacilitates the dispersal of the vinyl rubber filler throughout thecoating composition.

[0075] Application

[0076] The coating composition can be applied by a variety oftechniques, including, for example, rolling, brushing, spraying,squeeging, backrolling, pouring, troweling, or otherwise coating thesurface of the substrate. A preferred application technique is sprayingthe coating on the substrate. Combinations of these techniques may alsobe used including spraying the coating composition on the structuralunit and then rolling or brushing the sprayed coating composition toobtain a more uniform coating. The coating composition may be used onboth interior and exterior surfaces of structures, as well as on othersurfaces that need to be waterproofed.

[0077] Spraying the coating composition on the substrate requires aflowable coating composition. Many physical properties affectflowability, such as, for example, viscosity, temperature, and the like.Usually, as the viscosity is lowered, the easier it is to spray thecoating composition. Normally as the temperature of the material rises,the easier it is to spray the coating composition. Coating compositionsapplied year round in northern latitudes typically require specialattention to maintain the flowability of the composition.

[0078] The thickness of the coating will often depend on the particularsurface and material of the structural unit, as well as the projectedexposure to moisture. Rougher surfaces and surfaces in areas with moremoisture may require a thicker coating. In addition, thicker coatingsmay be used in situations where the coating may be subject topuncturing. For example, a coating on the exterior of a below-grademasonry unit, such as a foundation, should be thick enough to withstandbridging cracks that develop in the substrate and the backfillingprocess. Typical dry coating thickness range from about 5 to 100 mil(about 125 to 2500 μm), and preferably from about 40 to 60 mil (about1000 to 1525 μm). Thicker and thinner coatings may also be useddepending, in part, on the desired use of the structural unit.

[0079] Upon drying, the coating composition becomes a film. Typicaldrying times range from 4 to 24 hours. Longer or shorter drying timesmay be used depending on the thickness of the applied coatingcomposition, the air temperature and humidity and the desired amount ofsolvent that should be removed.

[0080] The coating composition of the present invention may be appliedby itself or in conjunction with another waterproofing system. Forexample, the coating composition of the present invention may be coatedon a structural unit, followed by the application of waterproofingsheeting. In addition, the coating composition of the present inventionmay be used with another coating to provide enhanced protection. Apreferred coating for use with the coating of the present invention is aflexible-film-forming composition, such as, for example, thecompositions described in Patent application Ser. No. 09/274,180 thatwas filed on Mar. 23, 1999. In one embodiment, the flexible-film-formingcomposition comprising an organic solvent and a polymeric binder resin,the polymeric binder resin having a styrene content less than 60 wt. %.Such polymers include copolymers having styrene and diene monomer unitswith a styrene content of less than 60%. wt, polymers having olefinmonomer units, copolymers having styrene and olefin monomer units with astyrene content of less than 60%. wt and mixtures thereof. The preferredcombination of the two coating compositions includes applying thecoating composition of the present invention between the substrate andthe flexible-film-forming coating.

EXAMPLES

[0081] The following examples further illustrate the invention. Theseexamples are merely illustrative of the invention and do not limit thescope of the invention.

[0082] Between one quart and several gallons of the coating composition(Tables 1 and 2 labeled A-C) were prepared using the following materialsand amounts: TABLE 1 Materials and Amounts for the Coating CompositionsA (kg) Xylene 1.89 Nevex ® 100 0.43 (Coumarone-indene resin) MIPS 3120.58 (Medium Impact Polystyrene) Palitinol 79 0.13 (Plasticizer) OptiWhite 0.21 (Filler) Wollastonite 0.68 (Filler) Talc 0.52 TitaniumDioxide 0.09

[0083] The polymers, hydrocarbon resin and titanium dioxide, werecombined in a vessel. The solvent (xylene and optionally mineralspirits) was then added. The solvent and other components were mixed for20 to 45 minutes. The mixing continued until the mixture appeared creamyand the particles in the mixture appeared uniform when viewed through afalling film of the mixture. Each coating was sprayed or brushed ontothe substrate. Each coating composition was allowed to dry on asubstrate, such as a masonry block. The resulting films were solid witha minimum of pinholing and had elastomeric qualities. TABLE 2 Materialsand Amounts for Coating Compositions B C (kg) (kg) Xylene 1.89 1.89Nevex ® 100 0.43 0.00 (Coumarone-indene resin) MIPS 312 0.58 0.58Palitinol 79 0.13 0.13 Opti White 0.21 0.21 Wollastonite 0.68 0.68 Talc0.52 0.52 Titanium Dioxide 0.09 0.09

[0084] Formula B shown in Table 2 illustrates another example of theinvention composition and is used in the viscosity tests that follow(Table 3). Formula C shown in Table 2 illustrates a coating compositionwithout hydrocarbon resin used in the viscosity tests that follow (Table4). “EEEE” in Table 4 indicates a value too high for the instrument toread.

[0085] Many of the components used in the Examples were available from avariety of manufacturers and distributors. For example, the Nevex 100®hydrocarbon resins were available from Neville Chemical Company(Pittsburgh, Pa.). MIPS 312 was available from Nova Chemicals. Palitinal79 was available from BASF (New Jersey). Wollastonite was available fromNYCO Minerals, Inc., (Willsboro, N.Y.). Opti White was available fromBurgess Pigment Company (Sandersville, Ga.). Talc, titanium dioxide,xylene, methylene chloride, and mineral spirits were available from avariety of manufacturers. TABLE 3 Brookfield Viscosity Results Formula BShear Shear Speed Torque Viscosity Stress Rate Temp Time Item # RPM %mPas N/m² 1/s ° C. MM:SS 1 2.5 20.6 20600 17.5 0.85 14.8 04:03 2 5.026.1 13050 22.2 1.70 14.8 02:00 3 10 34.2  8550 29.1 3.40 14.8 01:00 420 48.3  6037 41.1 6.80 14.7 00:30 5 10 34.1  8525 29.0 3.40 14.8 01:006 5.0 26.0 13000 22.1 1.70 14.8 02:00 7 2.5 21.1 21100 17.9 0.85 14.804:00

[0086] TABLE 4 Brookfield Viscosity Results Formula C Shear Shear SpeedTorque Viscosity Stress Rate Temp Time Item # RPM % mPas N/m² 1/s ° C.MM:SS 1 2.5 96.9 96900 82.4 0.85 14.8 04:01 2 5.0 EEEE EEEE EEEE 1.7014.8 01:59 3 10 EEEE EEEE EEEE 3.40 14.8 01:00 4 20 EEEE EEEE EEEE 6.8014.8 00:30 5 10 EEEE EEEE EEEE 3.40 14.8 01:00 6 5.0 100 50350 85.5 1.7014.7 02:00 7 2.5 91.6 91600 77.9 0.85 14.8 04:00

[0087] The present invention should not be considered limited to theparticular examples described above, but rather should be understood tocover all aspects of the invention as fairly set out in the attachedclaims. Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the instant specification.

I claim:
 1. A waterproofing composition, comprising: about 33 phr toabout 250 phr of an organic solvent; about 10 phr to about 50 phr of apolyindene; and about 50 phr to about 90 phr of a styrene polymer,having a styrene content of about 60 wt % or greater, selected from thegroup consisting of a copolymer having styrene and diene monomer units,a styrene homopolymer and mixtures thereof.
 2. The waterproofingcomposition of claim 1, wherein the diene monomer units includebutadiene, isoprene and mixtures thereof.
 3. The waterproofingcomposition of claim 1, wherein the styrene polymer has a styrenecontent of 85 wt. % or greater.
 4. A waterproofing composition,comprising: about 50 to about 150 phr of an organic solvent; about 30phr to about 50 phr of a polyindene; about 50 phr to about 70 phr of astyrene polymer, having a styrene content of about 60 wt % or greater,selected from the group consisting of a copolymer having styrene anddiene monomer units, a styrene homopolymer and mixtures thereof.
 5. Thewaterproofing composition of claim 4, wherein the diene monomer unitsinclude butadiene, isoprene and mixtures thereof.
 6. The waterproofingcomposition of claim 4, wherein the styrene polymer has a styrenecontent of 85 wt. % or greater.
 7. The waterproofing composition ofclaim 4, further comprising about 20 phr to about 600 phr of a filler